Variable speed control of powered surgical device

ABSTRACT

A surgical device includes a housing, a drive shaft, a motor, a control button, and a motor speed controller. The motor is configured to rotate the drive shaft that is disposed within housing. The control button is disposed on the housing and the motor speed controller is operably associated with the control button. The motor speed controller varies an angular velocity of the motor as a function of a percent of actuation of the control button between an unactuated position and a fully actuated position.

BACKGROUND 1. Technical Field

The present disclosure relates to surgical devices and, morespecifically, to speed control systems for powered surgical devices.

2. Discussion of Related Art

A number of surgical device manufacturers have developed product lineswith proprietary drive systems for operating or manipulating thesurgical device. In many instances the surgical devices include a handleassembly, which is reusable, and a disposable end effector or the likethat is selectively connected to the handle assembly prior to use andthen disconnected from the handle assembly following use in order to bedisposed of or in some instances sterilized for re-use.

Many of the existing end effectors for use with many of the existingsurgical devices or handle assemblies linearly advance a firing assemblyto actuate the end effector. For example, end effectors for performingendo-gastrointestinal anastomosis procedures, end-to-end anastomosisprocedures, and transverse anastomosis procedures, each typicallyrequire a linear advancement of a firing assembly in order to beoperated.

Existing handle assemblies advance the firing assemblies at apredetermined speed. In addition, some handle assemblies includefeedback systems that reduce the predetermined speed in response tosurgical conditions such as tissue thickness. However, a clinician usingthe surgical device lacks control of the firing speed of the handleassembly.

Accordingly, there is a need to provide a clinician with an ability tovary the speed of advancement a firing assembly based surgicalconditions observed by the clinician.

SUMMARY

In an aspect of the present disclosure, a surgical device includes ahousing, a drive shaft, a motor, a control button, and a motor speedcontroller. The motor is configured to rotate the drive shaft that isdisposed within housing. The control button is disposed on the housingand the motor speed controller is operably associated with the controlbutton. The motor speed controller varies an angular velocity of themotor as a function of a percent of actuation of the control buttonbetween an unactuated position and a fully actuated position.

In aspects, the motor speed controller includes a magnet and a HallEffect sensor. The magnet may be attached to the control button and theHall Effect sensor may be fixedly mounted within the housing.

In some aspects, the motor speed controller includes a light source, aset of louvers, and a photo sensor. The set of louvers may be disposedbetween the light source and the photo sensor. The set of louvers canhave a closed configuration in which the set of louvers prevent lightemitted from the light source from reaching the photo sensor and an openconfiguration in which at least a portion of light emitted from thelight source illuminates the photo sensor. The motor speed controllermay include a drive gear operably associated with the set of louvers totransition the set of louvers between the open and closedconfigurations. The control button may include a rod having a toothedrack that meshingly engages the drive gear to transition the set oflouvers between the open and closed configurations in response toactuation of the control button.

The function can be a linear function or a stepped function. When thefunction is a stepped function, the stepped function can be a two or athree step function. The stepped function can have a dead spot betweenabout zero percent and about five percent actuation of the controlbutton where the motor does not rotate the drive shaft.

In certain aspects, the surgical device includes a biasing memberdisposed about the control button to urge the control button towards theunactuated position. The biasing member can have a spring constant suchthat an actuation force required to actuate the control button linearlyincreases to affect actuation of the control button towards the fullyactuated position. Alternatively, the biasing member can have a firstspring constant and a second spring constant such that an actuationforce required to actuate the control button increases in a steppedmanner to affect actuation of the control button towards the fullyactuated position.

In another aspect of the present disclosure, a method of controlling anangular velocity of a drive shaft of a motor of a surgical deviceincludes actuating a control button of the surgical device a firstdistance towards a fully actuated position such that a motor speedcontroller transmits a control signal to the motor to rotate the driveshaft at a first angular velocity and continuing to actuate the controlbutton of the surgical device a second distance towards the fullyactuated position such that the motor speed controller transmits asecond control signal to the motor to rotate the drive shaft a secondangular velocity greater than the first angular velocity.

In aspects, continuing to actuate the control button of the surgicaldevice a section distance transitions a set of louvers towards an openconfiguration such that an amount of light emitted from a light sourcereaching a photo sensor increases. Alternatively, continuing to actuatethe control button of the surgical device a second distance can move amagnet closer to a Hall Effect sensor.

Further, to the extent consistent, any of the aspects described hereinmay be used in conjunction with any or all of the other aspectsdescribed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure are described hereinbelow withreference to the drawings, which are incorporated in and constitute apart of this specification, wherein:

FIG. 1 is a perspective view, with parts separated, of a surgical deviceand adapter, in accordance with an embodiment of the present disclosure,illustrating a connection thereof with an end effector;

FIG. 2 is a perspective view of the surgical device of FIG. 1;

FIG. 3 is a perspective view, with parts separated, of the surgicaldevice of FIGS. 1 and 2;

FIG. 4 is a cross-sectional view taken along the section line 4-4 ofFIG. 2;

FIG. 5 is an enlarged view of the area of detail of FIG. 4;

FIG. 6 is a graph depicting output speed of a motor of the surgicaldevice of FIG. 1 as a linear function of actuation of a control buttonof the surgical device of FIG. 1;

FIG. 7 is a graph depicting output speed of a motor of the surgicaldevice of FIG. 1 as a two-step function of actuation of a control buttonof the surgical device of FIG. 1;

FIG. 8 is a graph depicting output speed of a motor of the surgicaldevice of FIG. 1 as a three-step function of actuation of a controlbutton of the surgical device of FIG. 1;

FIG. 9 is a graph depicting output speed of a motor of the surgicaldevice of FIG. 1 as a stepped function of actuation of a control buttonof the surgical device of FIG. 1;

FIG. 10 is an enlarged view of the area of detail of FIG. 4 showing aset of louvers in a closed configuration; and

FIG. 11 is a view similar to the view of FIG. 10 showing the set oflouvers in an open configuration.

DETAILED DESCRIPTION

This disclosure relates generally to variable speed controls for poweredsurgical devices. The powered surgical devices include motor speedcontrols for varying the speed of motors of the powered surgical device.As detailed below, the motor speed controls may include a magnetdisposed on a control button and a Hall Effect sensor positioned on acontrol board adjacent the control button. As the control button isactuated, the Hall Effect sensor detects the magnetic field generated bythe magnet to determine the actuation of the motor speed control.Alternatively, the motor speed control may include a control button, alight source, a set of louvers, and a photo sensor. The control buttonis operably coupled to the set of louvers which are disposed between thelight source and the photo sensor and function to vary an amount oflight, emitted from the light source, that is received by the photosensor in response to actuation of the control button.

Embodiments of the present disclosure are now described in detail withreference to the drawings in which like reference numerals designateidentical or corresponding elements in each of the several views. Asused herein, the term “clinician” refers to a doctor, a nurse, or anyother care provider and may include support personnel. Throughout thisdescription, the term “proximal” refers to the portion of the device orcomponent thereof that is closest to the clinician and the term “distal”refers to the portion of the device or component thereof that isfarthest from the clinician.

A surgical device, in accordance with an embodiment of the presentdisclosure, is generally designated as 100, and is in the form of apowered hand held electromechanical device configured for selectiveattachment thereto of a plurality of different end effectors that areeach configured for actuation and manipulation by the powered hand heldelectromechanical surgical device.

As illustrated in FIG. 1, the surgical device 100 is configured forselective connection with an adapter 200, and, in turn, adapter 200 isconfigured for selective connection with an end effector or single useloading unit 300. As detailed herein, end effector 300 is a stapling endeffector; however, it is contemplated that the surgical device 100 maybe selectively connected to a plurality of end effectors that areconfigured to perform a variety of surgical procedures to tissue (e.g.,stapling, sealing, dissecting, and sampling).

As illustrated in FIGS. 1-3, the surgical device 100 includes a handlehousing 102 having a lower housing portion 104, an intermediate housingportion 106 extending from and/or supported on lower housing portion104, and an upper housing portion 108 extending from and/or supported onintermediate housing portion 106. Intermediate housing portion 106 andupper housing portion 108 are separated into a distal half-section 110 athat is integrally formed with and extending from the lower portion 104,and a proximal half-section 110 b connectable to distal half-section 110a by a plurality of fasteners. When joined, distal and proximalhalf-sections 110 a, 110 b define a handle housing 102 having a cavity102 a therein in which a circuit board 150 and a drive mechanism 160 issituated.

Upper housing portion 108 of handle housing 102 provides a housing inwhich drive mechanism 160 is situated. The drive mechanism 160 isconfigured to drive shafts and/or gear components in order to performthe various operations of the surgical device 100. In particular, drivemechanism 160 is configured to drive shafts and/or gear components inorder to selectively move tool assembly 304 of end effector 300 (FIG. 1)relative to proximal body portion 302 of end effector 300, to rotate endeffector 300 about a longitudinal axis “X” (FIG. 3) relative to handlehousing 102, to move anvil assembly 306 relative to cartridge assembly308 of end effector 300 between open and clamped positions, or to fire astapling and cutting cartridge within cartridge assembly 308 of endeffector 300 to eject staples (not explicitly shown) from the cartridgeassembly 308 and to advance a knife 309 through the cartridge assembly308.

The drive assembly 160 includes a first motor 80 that rotates a firstdrive shaft 82 and a second motor 90 that rotates a second drive shaft92. The first drive shaft 82 is operatively associated with the endeffector 300 such that rotation of the first drive shaft 82 firesstapling and cutting cartridge within the cartridge assembly 308. Thesecond drive shaft 92 is operatively associated with the end effector200 such that rotation of the second drive shaft rotates the endeffector 200 about the longitudinal axis “X” as detailed below. It iscontemplated that the first and second drive shafts 82, 92 may beoperatively associated with different functions of the end effector 200.Such functions can include articulation of the end effector, clampingtissue, firing staples and/or cutting tissue, etc.

Exemplary examples of electromechanical, hand-held, powered surgicaldevices and adapters are disclosed in commonly owned U.S. Pat. Nos.8,968,276 and 9,055,943, commonly owned U.S. Patent Publication No.2015/0157321, and commonly owned U.S. Provisional Patent ApplicationSer. No. 62/291,775, filed Feb. 5, 2016, entitled “HANDHELDELECTROMECHANICAL SURGICAL SYSTEM,” the entire contents of each of thesedisclosures are hereby incorporated by reference.

As illustrated in FIGS. 1-3, the handle housing 102 supports a triggerhousing 107 on a distal surface or side of the intermediate housingportion 108. The trigger housing 107, in cooperation with theintermediate housing portion 108, supports a pair of finger-actuatedcontrol buttons 124, 126 and rocker devices 128, 130. In particular, thetrigger housing 107 defines an upper aperture 125 for slidably receivinga first control button 124, and a lower aperture 127 for slidablyreceiving a second control button 126. Each one of the control buttons124, 126 is moved or actuated by a clinician to affect movement of theend effector 300.

The trigger housing 107 includes biasing members 134, 136 operablyassociated with the control buttons 124, 126, respectively. Each of thebiasing members 134, 136 is disposed about a respective control button124, 126 to bias the respective control button 124, 126 towards theunactuated position. The biasing members 134, 136 resist actuation ofthe control buttons 124, 126, respectively, such that an actuation forceis required to move each of the control buttons 124, 126 towards thefully actuated position. The biasing members 134, 136 can have a linearspring constant such that the actuation force linearly increases as therespective control button 124, 126 is actuated. Alternatively, thebiasing member 134 can include a first spring 134 a and a second spring134 b such that the actuation force increases in a stepped manner as thecontrol button 124 is actuated. Specifically, in a first step ofactuation of the control button 124, the first spring 134 a iscompressed and in a second step of actuation of the control button 124,the first and second springs 134 a, 134 b are compressed. It iscontemplated that the second biasing member 136 can also require astepped actuation force to actuate the control button 126. It isenvisioned that the first and/or second biasing members 134, 136 can beconstructed of a single spring having a spring rate that varies as thespring is compressed such that the actuation force increases in astepped manner or in an exponential manner as the control button 124,126 is actuated.

With reference to FIG. 4, the circuit board 150 includes first andsecond motor speed controls 10, 20 that are engaged by the controlbuttons 124, 126 to affect movement of the end effector 300. Each of thefirst and second motor speed controls 10, 20 are in communication withthe drive assembly 160 to affect rotation of the first and second driveshafts 82, 92, respectively. Specifically, the first motor speed control10 is in communication with the motor 80 to control the rotational speedof first drive shaft 82 and the second motor speed control 20 is incommunication with the motor 90 to control the rotational speed of thesecond drive shaft 92.

Referring also to FIG. 5, the first motor speed control 10 includes amagnet 12 and a Hall Effect sensor 14. The magnet 12 is mounted to thecontrol button 124 and is moveable towards and away from the Hall Effectsensor 14. The Hall Effect sensor 14 is mounted to the circuit board 150to determine a distance or gap to the magnet 12. From the distancebetween the Hall Effect sensor 14 to the magnet 12, the first motorspeed control 10 determines an extent that the control button 124 isdepressed. The first motor speed control sends a control signal to themotor 80 indicative of the position of the control button 124 to affectrotation of the first drive shaft 82, as described in greater detailbelow.

With additional reference to FIGS. 6-9, the control signal controls anoutput speed (i.e., angular velocity of rotation) of the motor 80 as afunction of actuation of the control button 124. The actuation of thecontrol button 124 is measured from an unactuated or nondepressedposition as 0% actuation and a fully depressed position as 100%actuation. With particular reference to FIG. 6, the output speed of themotor 80 is a linear function of the percent of actuation of the controlbutton 124. Specifically, the motor 80 rotates a percent of its maximumoutput speed that correlates to a percent of actuation of the controlbutton 124.

Alternatively, as shown in FIGS. 7-9, the output speed of the motor 80is a step function of the percent of actuation of the control button124. With reference to FIG. 7, the output speed of the motor 80 is atwo-step function of the percent of actuation of the control button 124.Specifically, the control button 124 has a dead zone between 0% andabout 5% of actuation where the motor 80 does not rotate, a first stepbetween about 5% and about 50% of actuation of the control button 124where the motor 80 rotates at a low speed of about 50% of its maximumoutput speed, and a second step between about 50% and 100% of actuationof the control button 124 where the motor 80 rotates at a high speed atits maximum output speed.

With reference to FIG. 8, the output speed of the motor 80 is a threestep function of the percent of actuation of the control button 124.Specifically, the control button 124 has a dead zone between 0% andabout 5% of actuation where the motor 80 does not rotate, a first stepbetween about 5% and about 40% of actuation of the control button 124where the motor 80 rotates at a low speed of about 25% of its maximumoutput speed, a second step between about 40% and about 75% of actuationof the control button 124 where the motor 80 rotates at a mid-speed ofabout 50% of its maximum output speed, and a third step between about75% and 100% of actuation of the control button 124 where the motor 80rotates at a high speed at its maximum output speed. Other ranges andpercentages are contemplated within the scope of the present disclosure.

With reference to FIG. 9, the output speed of the motor 80 can be astepped function with a plurality of steps that increase the outputspeed of the motor 80 in response to the percent of actuation of thecontrol button 124.

Table 1 below shows the output speed percent of the motor 80 as apercent of actuation of the control button 124 for each of the functionsdetailed above.

TABLE 1 Two- Three- Linear Step Step Stepped Function Function FunctionFunction Percent of 0 0 0 0 0 Actuation 5 5 0 0 0 10 10 50 25 10 15 1550 25 10 20 20 50 25 20 25 25 50 25 20 30 30 50 25 30 35 35 50 25 30 4040 50 25 40 45 45 50 50 40 50 50 50 50 50 55 55 100 50 50 60 60 100 5060 65 65 100 50 60 70 70 100 50 70 75 75 100 50 70 80 80 100 100 80 8585 100 100 80 90 90 100 100 90 95 95 100 100 90 100 100 100 100 100Output Speed Percent

With reference to FIGS. 4, 10, and 11, the second motor speed control 20includes a light source 22, a photo sensor 24, a set of louvers 26, anda drive gear 28. The light source 22 is disposed within the loweraperture 127 of the trigger housing 107 and the photo sensor 24 ismounted to the control board 150 and positioned to receive light emittedfrom the light source 22. The set of louvers 26 is positioned betweenthe light source 22 and the photo sensor 24. The set of louvers 26 has aclosed or substantially closed configuration (FIG. 10) in which the setof louvers 26 prevents or limits light, emitted from the light source22, from reaching the photo sensor 24, and an open or substantially openconfiguration (FIG. 11) in which the set of louvers 26 allows at least aportion or a majority of light, emitted from the light source 22, toreach the photo sensor 24.

The set of louvers 26 includes a first louver 26 a, a second louver 26b, and a third louver 26 c that are operably coupled to a drive belt 29extending from the drive gear 28. The control button 126 includes a rod126 a extending towards the circuit board 150. The rod 126 a includes atoothed rack 126 b that is meshingly engaged with teeth 28 a of thedrive gear 28. As the control button 126 is actuated from an unactuatedposition (FIG. 10) towards an actuated position (FIG. 11), the toothedrack 126 b rotates the drive gear 28 which pivots the set of louvers 26from the closed configuration towards the open configuration. As the setof louvers 26 pivots towards the open configuration, an amount of lightemitted from the light source 22 and received by the photo sensor 24increases. As shown, the set of louvers 26 includes three louvers 26a-c; however, it is contemplated that the set of louvers 26 can include1, 2, or more than three louvers.

In response to receiving light emitted from the light source 22, thephoto sensor 24 sends a control signal to the motor 90 to affectrotation of the second drive shaft 92. The control signal controls anoutput speed (i.e., angular velocity of rotation) of the motor 90 as afunction of the amount of light received by the photo sensor 24 andthus, actuation of the control button 126. The actuation of the controlbutton 126 is measured from an unactuated or nondepressed position as 0%actuation and a fully depressed position as 100% actuation. Withparticular reference to FIG. 6, the output speed of the motor 90 is alinear function of the percent of actuation of the control button 126.Specifically, the motor 90 rotates a percent of its maximum output speedthat correlates to a percent of actuation of the control button 126.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Any combination ofthe above embodiments is also envisioned and is within the scope of theappended claims. Therefore, the above description should not beconstrued as limiting, but merely as exemplifications of particularembodiments. Those skilled in the art will envision other modificationswithin the scope of the claims appended hereto.

What is claimed:
 1. A surgical device comprising: a housing; a driveshaft; a motor for rotating the drive shaft disposed within the housing;a control button disposed on the housing; and a motor speed controlleroperably associated with the control button, the motor speed controllervarying an angular velocity of the motor as a function of a percent ofactuation of the control button between an unactuated position and afully actuated position, the motor speed controller including a lightsource, a set of louvers, and a photo sensor.
 2. The surgical deviceaccording to claim 1, wherein the set of louvers is disposed between thelight source and the photo sensor, the set of louvers having a closedconfiguration in which the set of louvers prevent light emitted from thelight source from reaching the photo sensor and an open configuration inwhich at least a portion of light emitted from the light sourceilluminates the photo sensor.
 3. The surgical device according to claim2, wherein the motor speed controller includes a drive gear operablyassociated with the set of louvers to transition the set of louversbetween the open and closed configurations.
 4. The surgical deviceaccording to claim 3, wherein the control button includes a rod having atoothed rack that meshingly engages the drive gear to transition the setof louvers between the open and closed configurations in response toactuation of the control button.
 5. The surgical device according toclaim 1, wherein the function is a linear function or a steppedfunction.
 6. The surgical device according to claim 5, wherein thestepped function is a two-step function.
 7. The surgical deviceaccording to claim 5, wherein the stepped function is a three-stepfunction.
 8. The surgical device according to claim 5, wherein thestepped function has a dead spot between about 0% and about 5% ofactuation of the control button where the motor does not rotate thedrive shaft.
 9. The surgical device according to claim 1, furthercomprising a biasing member disposed about the control button to urgethe control button towards the unactuated position.
 10. The surgicaldevice according to claim 9, wherein the biasing member has a springconstant such that an actuation force required to actuate the controlbutton linearly increases to affect actuation of the control buttontowards the fully actuated position.
 11. The surgical device accordingto claim 9, wherein the biasing member has a first spring constant and asecond spring constant such that an actuation force required to actuatethe control button increases in a stepped manner to affect actuation ofthe control button towards the fully actuated position.
 12. A method ofcontrolling an angular velocity of a driveshaft of a motor of a surgicaldevice, the method comprising: actuating a control button of thesurgical device a first distance towards a fully actuated position suchthat a motor speed controller transmits a control signal to the motor torotate the drive shaft at a first angular velocity; and continuing toactuate the control button of the surgical device a second distancetowards the fully actuated position to transition a set of louverstowards an open configuration such that an amount of light emitted forma light source reaching a photo sensor increases such that the motorspeed controller transmits a second control signal to the motor torotate the drive shaft a second angular velocity greater than the firstangular velocity.